Latest Technology Adds Excellence in Weft Knitting
Weft knitting is gaining more-n-more popularity these days as it offers excellent output turnover, low cost of production, and a large no. of variations in knitted fabrics. We define knitting as a process of making a piece of fabric from the loops of the yarn. Knitting is an ancient art. In ancient times people used to do knitting with their hands. Nobody knows from where and when the technique of knitting got originated. People of Persia were very much fond of art, and they were assumed to be the inventors of the method of knitting. Some other countries like Israel, Syria and Jordan are also believed to develop the craft of making the weft knitted fabrics. People living in North Africa mainly in the traditionally Islamic regions also had a significant role in developing the knitting technique. Even the attire of the people living in middle-east symbolises the craft of weft knitting. Ancient paintings also reveal that during the late eighteenth and early nineteenth century the women of the middle- east mostly worn the weft knitted fabrics. During ancient times a lot of other things were also knitted traditionally, and these include - pullovers, skirts, cardigans, men's underwear, swimwear and sportswear. With the invention of the knitting machines, there has occurred an enhancement in the speed of production of the knitted fabrics. At present, large no. of advancements are taking place in the knitting machines. Now, we introduce computer chips in the knitting machines to control them. Introduction of computer chips in the machine also allow permutations with the knitting designs. These days, knitted fabrics have become one of the most fashionable clothes. Knitted fabrics offer us an advantage of providing a variety of designs thus giving every cut of cloth a unique look. At present, people are using knitted clothes as their everyday wear. As the population of the people is increasing day by day; therefore, the demand for clothes is also growing due to which the textile industry is evolving very rapidly. The quality of the yarn decides the excellence of the finished product. If there are more broken ends in the yarn, then the quality of the yarn gets deteriorated. But, if it is continuous in length, then there will not be any odd tiny mounds in the cloth thus giving it a smooth finish. Good quality winding produces few broken ends thus contributing in the finished quality of the fabric. In today's market, the average quality of yarn is available due to which we have upgraded our knitting machines so that we can make the best most out of whatever quality of yarn is available. Depending upon the quantity of the automatic needle sets that are necessary for making the weft knitted fabrics, we can classify the weft knitting and weft knitted fabrics into single or double types. We can classify the industrial weft knitting machines into either flat-bed or circular weft knitting machines.
The process of knitting can be of two types: Weft knitting and warp knitting. We can form a knitted fabric by using the weft as well as warp knitting techniques.
The below-mentioned points will highlight the recent developments that are occurring mainly in the weft knitting sector:
Creel Unit The main function of the creel unit is to perform the procedures like package mounting, feeding of the yarn etc. The major part of the creel unit includes the fly removal system which is present at the one end of the creel. Fly removal system takes care of the flies that can affect the quality of the finished product. Entry of a lot of flies can influence the process of production by jamming the entire running of the machine. To circumvent such a thing, we insert a tube in the creel unit which usually extends from the beginning of the yarn mounting place to the wheel which feeds the threads to form the cloth. By inserting the tube, we can prevent the deterioration of the quality of the production. Nowadays, we usually compress the air and polish the material for threading. The primary benefit of using the polished material is that it offers very less friction thus helping us in maintaining the quality of the thread. For making the different patterns we have to change the packages very often, but this can interfere with the enclosure thus making the whole procedure cumbersome. But if we will change the packages at a ceasing frequency, then we can make the process a little easy. To change the packages at a ceasing frequency, we should use the heavy packages. At present, we commonly use the packages weighing around 2 Kilos.
Yarn Feeder The primary function of the yarn feeder is to pull out the yarn from the package and then to adjust it so that the needles get placed in the uniform tension to perform the process of knitting. It is essential to maintain the uniform tension throughout the process so that we can make the unique length of the yarn per stitch for the whole length of the cloth. The quality of the knitting machine also determines the uniform pulling of the yarn length. While keeping in place the basic concept, we are making improvements in the yarn feeders from time to time. With the insertion of the improved feed wheel and the tensioner now the knitting machines have become more efficient. The super-positive feed wheel, the yarn tensioner and the motion stopper along with the multiple loops increases the efficiency of the machine. Due to the various improvements in the yarn feeders now there occurs a very less amount of slippage which in turn helps in upgrading the quality of the cloth. Latest advanced feeders which we use for circular knitting are very easy to navigate. Moreover, these feeders with the new technology incorporated in them are quite durable and need less maintenance. Nowadays, we protect the whole unit of the yarn feeder with a plastic cover which makes them very light in weight, results in less vibration and eliminates the static charge. To enhance the process of the yarn feed, we provide some of the machines with the electronic control mechanism. At present, we have a lot of mechanisms available to us which ensure the perfect tension. To facilitate less amount of filamentation we always research the materials before using them in the spooler. We provide the machine with a hard coating to resist the process of corrosion and wearing off. Now, we fix a clutch with an open-design in the machine which makes the cleaning easy. Ceramic yarn guide is also available which helps us in preventing the short circuit of the vibration tensioner containing the magnetic rings. The machine has to stop periodically in between the weave to prevent irregular or intermittent type of feed, as it happens in the case of the jacquard knitting machine.
Cam and needle Cam unit is the most crucial part of the knitting machine. More is the efficiency of the knitting machine; better will be the design as well as the quality of the fabrication. We arrange the cam and the needle in the cylinder. The cylinder and the dial generally work in unison to move the needle. The needles make the cylinder as well as the dial to get involved in the knitting process more directly. We also have a backup system in the machine which ensures the double knitting arrangements thus making the process of knitting a no trouble operation.
Needles The needles which we use for making smooth patterns are very delicate and can withstand only a certain amount of tension. Moreover, designing is an essential part for which the needles have to work for a long time. Nowadays we keep various parameters in our mind while making the needles which includes new improved surface quality, heat treatment, the shape of the shank and head geometry. While making circular stitching styles, the main problem which we face is the bending of the needles. But to solve the issue of bending of needles, we now design the circular needle hooks. We also have cone-shaped needle hooks for increasing the efficiency of the needle without compromising the space for the yarn. We can see improvements in the design of the shank which holds the three needles and take care of the machine vibration.
Sinkers The primary role of the sinker is to provide a sliding movement which in turn supports the loop. But the sliding can result in friction. This concept caused us to improve the surface quality of the fabric. Now we incorporate the latest advanced parts in the machine which includes: an insertion pusher plugging over the yarn space and a knock-over sinker for loop doubling over. We take care that the curves get properly designed having a surface finish in them. The significant benefit of this type of design is that it also reduces the yarn tension.
Take-down For gaining the quality finish, we need to have a steady stitching operation along with the fabric provision and the machine acceptance to pool it for the weave. There should be a uniform tension throughout the circumference of the unit. It is challenging to attain a consistent tension because the fabric is usually available in the circular pattern. Due to the circular pattern, we have to place the fabric on the take-down roller in the form of the double-layered straight fabric. Now we have an excellent open-width fabric cutter as well as take-up with black-and-white Lycra wheels which appear grey as long as the fabric is running and become black and white when there occurs breakage of the yarn. These latest features help us in increasing fabric take-down performance. We do the calculations by using EPA thus getting an even take down as well as rolling of the yarn without having any crunch in the entire width of the fabric.
Stop and start in batches: We roll the knotted fabric to easily transport it to other places for carrying out the various procedures. For keeping the efficiency of the machine high, we make less number of rolls, but at the same time, we increase the size of the roll. There are various devices like TOP, i.e. the Synchronised Take-down Plaiting Device, speed adjusting VDQ pulleys designed by the Shelton which carefully smother the conic fabric into the box. We then transport this box containing the fabric to the Shelton Verifab SR where we slit the box, open it and scrutinise it. After the inspection, the Verifab SR machine then removes the curl if any present in the fabric by using its three de-curling stations and then we re-roll the fabric into the machine. Nowadays most of the circular knitting machines have easily fitted TOP in them. Machines also have a plaiting function which allows the larger batch sizes.
Drive:For the smooth operation of the knitting machine now we use frequency controlled asynchronous motor with the digital control system in the machines.
Control systems:The latest advanced features incorporated in the control systems are as follows: 1. Now we have digital control systems. 2. We are using modern consoles as the display panels. 3. Latest control panels are capable of stopping the motion of the machine whenever there occurs any breakage of the thread. 4. Control systems now have centralised lubrication systems.
Contact us: Our company Bharat Machinery Works manufactures as well as supplies the highly efficient knitting machines that perform at a higher pace. We always keep on upgrading our knitting machines from time to time according to the latest advanced technologies. We try to fulfil the ever-increasing demands of our customers by providing them with the newest knitting machines. Moreover, for gaining superior
performance, our skilled professionals always check every knitting machine on various parameters before the final dispatch of the machines. Our knitting machines are perfect for increasing productivity. So, whenever you require the best quality knitting machine at an affordable price then contact our company Bharat Machinery Works.